Method and apparatus for applying cover material to book cores and cases



Feb. 7, 1961 G. HANTSCHO METHOD AND APPARATUS FOR APPLYING COVERMATERIAL TO BOOK CORES AND CASES 4 She ets-Sheet 1 Filed July 13. 1955INVENTOR $5626: AQ/vmyo 2L5 ATTORNEY 4 Sheets-Sheet 2 G. HANTSCHO METHODAND APPARATUS FOR APPLYING COVER MATERIAL TO BOOK CORES AND CASES Feb.7, 1961 Filed July 13, 1955 Feb. 7, 1961 G. HANTSCHO 2,970,

METHOD AND APPARATUS FOR APPLYING COVER MATERIAL TO BOOK CORES AND CASES4 Sheets-Sheet 3 Filed July 13, 1955 Q LI INVENTOR 92-024: ,klvrs'c/lafiglmv Feb. 7, 1961 s. HANTSCHO 2,970,634

METHOD AND APPARATUS FOR APPLYING COVER MATERIAL TO BOOK COREIS ANDCASES 4 Sheets-Sheet 4 Filed July 13, 1955 INVENTOR 427M745 fiiwvrrcfi/aM 1/6 ATTORNEY METHOD AND APPARATUS FOR APPLYING MATERIAL TO BOOK CORESAND A George Hantscho, Tuckahoe, N.Y., assignor to George HautschoCompany Inc., a corporation of New York Filed July 13, 1955, Ser. No.521,699

14 Claims. (Cl. 154--1.8)

This invention relates to the manufacture of book covers and cases, andsimilar articles, and more specifically concerns a method and apparatusfor fabricating book covers and cases of the type embodying stiffeningmembers covered by cloth, paper or other similar material.

The manufacture of book covers has presented numerous problems to theindustry and the serious limitations of present procedures and apparatushave resulted in materially increased fabrication costs. Most booksembodying covers having stiffening members therein utilize some form ofdesign or lettering for identifying the book that must be exactlycoordinated and aligned with the stiffening members. To attain this end,prior methods have involved steps of first covering the stiffeningmembers and then printing or embossing the completed cover. In thealternative, pre-cut portions of the covering material are printed andthen such pre-cut portions are applied to the stiffening members. Ineither case the costs involved are high and the process is of necessitya relatively slow and laborious one. Moreover prior devices for merelyassembling the elements of covers to be subsequently printed haverequired a change in the direction of movement of the cover during thefabricating process and in many cases intermittent operations have beenemployed. These factors of course materially slow up the fabricationrate and contribute substantially to the cost of the finished article.

Accordingly, this invention contemplates the provision of a high speedcontinuously operating machine and method for fabricating book covers,cases and other similar articles that can be readily adapted to handle awide range of cover sizes and functions to perform all operations whilethe covers move continuously in a substantially uninterrupted paththrough the apparatus. This end is attained through the utilization ofimproved means for folding the covering material about all four edges ofthe core or stiffening members as they are transported. Moreover, theinvention further contemplates utilization of cover material inpreprinted continuous web form which greatly simplifies the process andapparatus and avoids the added costs in severing the covering materialinto sheets of predetermined size as heretofore generally practiced inthe case of prior devices.

A further object of the invention resides in the provision of a new andimprovedmethod and apparatus so that printed covering material preparedin roll form may be used directly in the cover fabricating apparatus.This is attained through a system for correlating a continuous strip ofpreprinted cover material with thecore material so that the designs willbe exactly and precisely positioned on the finished covers. This systemnot only controls the process in a manner that automatically compensatesfor deformations of the printed cover material either by reason ofelongation or shrinkage, but insures automatic phasing so that thepre-cut cores or stiffening material cannot be fed onto the covermaterial out'of step with the cover design.

- ...'Ihe above and other objects and advantages will be.-

States Patent come more apparent from the following description andaccompanying drawings forming part of this application.

The accompanying drawings show, for purposes of illustrating the presentinvention, one embodiment in which the invention may take form it beingunderstood that the drawings are illustrative of the invention ratherthan limiting the same.

In the drawings:

Fig. 1 is a diagrammatic view of the invention in perspective andillustrating certain principles thereof;

Fig. 2 is a side elevational view of a. portion of the apparatus of Fig.1 to illustrate other features thereof;

Fig. 3 is a side elevation of one embodiment of the invention;

Fig. 4 is a plan view'of the apparatus illustrated in Fig. 3;

Fig. 5 is a crosssectional view of Fig. 4 taken from along the line 5-5thereof;

Fig. 6 is a diagrammatic view of edge creasing cams to illustrate ingreater detail the operation thereof;

Figs. 7 and 8 are plan views of the left hand cams of Fig. 6 insuccessive positions during a single cycle of operation;

Figs. 9 and 10 are cross sectional views of Figs. 6 and 7 taken alongthe lines ?9 and til-iii respectively;

Figs. ll, 12 and 13 are plan views of the right-hand cam of Fig. 6showing successive positions of the cam during a single cycle ofoperation; and

Fig. 14 is a cross sectional view of Fig. 12 taken along the line ltd-14thereof.

Broadly the invention provides a high speed system for assemblyiug bookcovers and cases wherein all steps in the process are carried out whilethe covers are in motion. In other Words the covers or parts thereof arecontinuously moving at all times and in no instance is the coverentirely stationary for the purpose of performing an opera: tion orchanging its direction of transport. In the assembly of the web ofcovering material with the cores, the feeding means are correlated onewith the other so that precise coordination is attained. Thus eachsuccessive design on the continuous strip of cover material isaccurately coordinated and aligned with the core material. To facilitatean understanding of the invention, reference is made to Figs. 1 and 2which illustrate the several steps in the assembly of the core and covermaterials.

In the fabrication of book covers, the core usually comprises two piecesof. stiffening material 19 and 11 which form the front and backstiffness for the book covers and a central member 12, usually oflighter weight material, which will ultimately overlie the book binding.While the central section 12 is illustrated as forming part of the corematerial, it is apparent that its use is optional. The covering materialfor the core is in the form of a roll 13 that may have repeated coverdesigns thereon spaced one from the other an appropriate distance sothat when the successive designs are severed from the strip, sufficientmaterial remains to be folded over the edges of the cores in the mannerillustrated. In the actual process of assemblying the covers the threesections of core material it), 11 and 12 are glued to the cover materialand then the marginal edges are folded over the edges of the core toform a completed structure ready to receive the book to be boundtherein.

In Figs. 1 and 2, the cover material 13 is fed over a guide roller 14and then between successive sets of power drivenpressure rollers 15-l5'to 2tl-2tt' inclusive which control the transportation of the cover andcore materials. While not illustrated in these figures, the covermaterial is coated with a cement or glue prior to its entrance betweenthe rollers l5l5. .As the cover material is fed between the driverollers, sets of core sections it) to 12 are successively fed betweenthe rollers --15' by suitable feeding means 21. The action of the feeder21 is accurately correlated with the speed of the cover material 13between the rollers 1515' to -49 so that accurate and precisecoordination between the two is maintained at all times.

As each set of core sections iii to 12 is cemented firmly to the covermaterial 13 by the action of pressure rollers 15-i5, they successivelypass a first pair of cutting blades 22 suitably mounted to producediagonal corner cuts on each edge of the cover material and adjacent theouter corners of the trailing edge of each set of core sections. Thenext step in the process constitutes the provision of a second set ofdiagonal cuts adjacent the outer corners of the leading edge of each setof core sections by means of cutting blades 23 similar to the blades 22.This second set of cuts removes a small triangular piece of material 24from each edge of the cover material and leaves a pair of V-notches 25.In order to insure proper operation of the knives 22 and 23, theiractuation is precisely coordinated with the feeder 21.

After the cover material has been notched between successive sets ofcore sections, it then passes a fold over station having a pair ofcurved guides 2626' which engage the marginal sections, the covermaterial extending from the outer edges of the core sections 10 and 11.These guides fold this marginal cover material over onto the top side ofthe core whereupon it is permanently secured by the pressure rollersi.717. As each cover assembly passes between the pressure rollers 1.717'it is picked up by the next set of rollers 1818 so that it is positivelydriven forwardly at all times and at a predetermined speed. As eachcover assembly engages the rollers 19-19, the transverse cutter 27severs it from the preceding cover assembly along a line determinedgenerally by the apices of the V-notches 25. This cutter, as in the caseof cutters 22 and 23, is coordinated with. the operation of the feeder21.

After the marginal edges 28 and 29 of the web 13 have been folded overthe outer edges of the stifiening members by the guides 26 and 26, it isdesirable to press down the portions of the marginal edges 28 and 29that extend beyond the leading and traiing edges of the core sectionslit) and 11. These overlapping portions or corners are denoted by thenumerals 30, 30' and 33, 31. Creasing or tucking of these portions isattained by means. of two pairs of rotatably supported cams or fingers32, 32 and 33, 33'. These cams are rotated in synchronism with themovement of the Web 13 and periodically engage the successive cornerportions to flatten or score them and produce a tighter and more compactcorner. Operation of these cams will be discussed more fully inconnection with Figs. 6 to 14.

Referring again to the cutter 27, the severed cover assembly, while inengagement with the pressure rollers 1919, is moved into engagement witha rotating plate 34, forming the final turn-in station. This platefunctions to bend the leading marginal edge 35 of the web upwardly asshown in Fig. 2. Continued forward motion of the cover assembly foldsthe edge 35 backwardly as shown in dotted outline whereupon it is pickedup by the pressure rollers 36 and at. These rollers move the coverassembly forwardly and into the notch 37 in cushioning bar 37. This baris slidably mounted on a track 38 and is moved backwardly againstsuitable com pression springs 39, so that the trailing edge 40 of thecover assembly can be moved downwardly over the surface. of shield 41which overlies a portion of the periphery of roller 36. The cover isforcibly moved down under the action of a rotary depressor 42. Thisaction rolls the edge 4%) tightly over the edge of the cores 10 to 12whereupon the spring loaded bar 37 moves the cover into engagement withrollers E6 and 43 to complete the last marginal fold and discharge thefinished cover from the apparatus.

The coordination of the speed of the cover material 13 with the feedingmeans 21 for feeding said core sections 10 through 12 is preferablyaccomplished in the following manner. One edge of the cover material 13is provided with a series of marks or lines 44 along one edge thereof asillustrated in Fig. 1 and it is preferable to have at least two or'threesuch marks in the distance comprehended by a section of the materialforming'a single cover. While perforations may be employed instead ofthe marks 44, it is preferable to use the marks as they can be appliedduring the actual printing process which automatically coordinates themwith the cover design. Moreover, these marks are positioned so that theybe wholly on the margin (28 or 29) and are completely covered when thebook and cover are finally assembled.

This series of marks 44 are utilized to coordinate the web feed with thecore feed 21 by means of suitable photoelectric devices and coordinatedspeed controlling means. More specifically the marks 44 are detected byphotoelectric means comprising a light source 45 and lens 46 forfocussing a narrow beam of light onto the marks 44 and reflected lightis picked up by a photocell generally denoted by the numeral 47. Thiscell 47 is connected to an electronic correlator 48 which, as will beshown, coordinates the speed of the web 13 with the core feeding means21. While the marks 44 may be of any desired color, it is of courseimportant to have contrasting marks.

Considering now the driving means for the apparatus in which the powersource is preferably an electric motor 49 connected to a suitable sourceof electrical energy, this motor is arranged to drive a variable speedchanger 50 through a suitable mechanical coupling 51. The motor 49 alsodirectly drives the cutting blades 22, 23 and 27, the rotary platemembers 34 and 42, and actuates the feeding means 21 so that thesedevices operate in exact synchronism.

Inasmuch as the cover material 13 can either stretch or shrink, it istherefore important that its speed be governed in such a manner that apredetermined num: ber of cover designs are fed into the machinecorresponding to the rate at which the core material is fed to themachine. Should the cover material stretch slightly it is apparent thatit must be fed more rapidly in order to attain absolute alignment ofeach cover design with its associated set of core sections. Accordingly,means are provided in the form of a perforated disc 52 directly coupledto and rotated by the motor 49. A series of pulses are provided by meansof a photoelectric device. consisting of a source of light 53, a lens 54and a photoelectric cell SS, the source of light and the photocell beingon opposite sides of the perforated disc. Rotation of the disc thereforeproduces a series of pulses corresponding to the speed of the motor 49and these pulses" are fed by suitable e'ectric wires to the electronicco'rrelator 48.

The correlator 48 may be of any appropriate design that will accept astandard pulse such as the pulses received from photocells 47 and 55 andproduce a'voltage corresponding in polarity and magnitude to therelative phase difference and magnitude of such difference between thesignals. This voltage is utilized to operate a control motor 56 having ashaft 56 coupling it with the speed change mechanism 58 so that rotationof the motor 56 in onedirection or the other will vary the speed on theoutput shaft 57 relative to the input shaft 58. Since the drive rollersi4 and i5i5'. to 2-3 -20.' and '3ri-36' are all coupled one with theother and driven by the variable speed shaft 57 by gearing to bedescribed, it is apparent that any shift in the frequency that willautomatically adjust the speed of the cover mate'rial to coordinate withthe speed of the motor 49.

Thus should the web 13 become stretched the: else tronic correlatorwouldimmediately sense a relative decrease in speed of the marks 44 past thephotoelectric cell 47 and this would result in a modification of theratio of the speeds of the speed reducer shafts 57 and 58 to the speedof the cover material with reference to the speed of operation of thefeeder 21 and cutting devices as described.

Conversely should the material contract, the electronic correlator wouldcause a proportional decrease in the speed of travel of the covermaterial 13. In this way the marks provide an absolute control governingthe rate at which designs are fed into the apparatus. Therefore absolutealignment of each set of core sections with a corresponding design onthe cover material is attained and the degree of accuracy of suchalignment can be controlled by the number of marks 44 employed. Anincrease in the number of marks on the cover material and acorresponding increase in the number of holes 52 in the disc 52 willproduce a higher frequency and enable the electronic correlator 48 tofunction more frequently to correct the relative speeds of the motor 49and the covering material 13. If desired, means in the form of a secondseries of marks, as for instance the perforations 59 on the web 13 maybe utilized together with one or more enlarged openings 60 in the disc52 in order to provide a synchronizing signal electrically solutephasing of the covering material with each set of core sections andprevent the core feeding means from being locked in with the covermaterial so that core sections are positioned at points overlappingsuccessive designs. Thus should the machine be started in such a mannerthat each set of core sections is not properly aligned with each designon the covering material, this phasing procedure will automaticallyeffect proper coordination.

Figs. 3 through 14 show one embodiment of apparatus for carrying out theprocess and system for making book covers and cases as illustrated anddescribed in connection with Figs. 1 and 2. In general the machinecomprises a pair of longitudinal frame members 61 and 62 that aresecured one to the other by a series of cross members such as themembers 63 and other intervening supports as may be desired. Thisstructure is supported in a generally horizontal position by suitableupright supporting members 64, 65 and 66 so that the top of theapparatus is in a convenient position for making the necessaryadjustments and observing the machine while it is in operation. The rollof web or cover material 13 may be disposed in any suitable positionbeneath the machine and is fed between the rolls 14 and 14 with theprinted side upwardly as illustrated. Between the pair of frame members64 is a receptacle 67 containing a suitable glue or cement applied tothe under or plain side of the web 13 by means of the transfer rolls 68,69 and 14 respectively. The cover material with glue applied to thenon-printed side thereof then passes upwardly and between the rollers-45 to -20 inclusive and 3636 as described in connection with Figs. 1and 2. V t

The transporting rollers 1515' to 20-2tl' and 36-- 36 aresupported bythe frame members 61 and 62 while the rollers 14-14, 68 and 69 aresupported by the pair of frame members 64v and all are driven insynchronism one with the others. The remaining elements of the machinesuch as the feeding means 21, cutters 22, 23 and 27, cams 32-32' and3333' and the rotary plates 34 and 42 are driven in unison and at aspeed selected relative to the rollers.

Considering now the driving means, the main drive motor 49 is supportedbeneath the frame members 61.

and 62 by means of a suitable shelf 70 carried by the upright supports65 and 66. Alongsidev the motor is the speed changing device 50supported on the upright member 65 by means of a suitable'shelf orbracket 71. The input shaft 58 of the speed changer carriesa sprocketwheel 72 that is coupled by means of a chain 73 to a sprocket wheel 74on the shaft of motor 49. The driving shaft 57 of the speed changer iscoupled by means of a pair of beveled gears 75 and 76, a drive shaft 77and beveled gears '78 and 79 to a transverse shaft 80 carrying a spurgear 81. This spur gear meshes with coopcrating gears carried by theshafts of rollers 14 and 14' to effect positive drive and coordinationtherebetween.

, The rollers 63 and 69 are idler rolls in pressure contact one withtheother and with the driven roller 14' for transferring glue from thereceptacle 67 to the underside of the core material 13. If desired,however, these rollers may be positively driven.

The rollers 15 and 15 are driven by a sprocket wheel 82 on shaft 80, achain 83 and a sprocket wheel 84 carried by the shaft of roller 15. Therollers 16 and 16 are driven from the shaft 57 of the speed changemechanism 50 by means of a sprocket wheel 84' on the shaft 57, a chain85 and a sprocket wheel 86 on the shaft of roller 16. In addition therollers 17, 20 and 36 are driven from the shaft of roller 16 by means ofa sprocket wheel 87, chain 88 and sprocket wheels 89, 90 and 91 carriedby the shafts of .rollers 17, 20 and 36 respectively. The rollers ls and19 are in turn driven from a sprocket wheel 92 on the back side of themachine, chain 93 and sprocket wheels 94 and 95. Spring loaded pressureadjusting devices 96 and 97 press on the roller 15 so that apredetermined pressure can be applied to firmly cement the core sections10, 11 and 12 to the, cover material.

With the foregoing arrangement the cover material or web 13 is fed at auniform rate of speed through the entire machine and the absolute speedis governed by the photocell 47 shown in Fig. 1. In Figs. 3 to 5, thephotocell 47, together with the light source 45. lens 46 and otherassociated equipment, are shown in the form of an integral unit 98 whichperforms the same function as the elements diagrammatically shown inFig. 1.

Having described the feeding and transporting means for the web 13 andthe separated cover assemblies, the structure and operation of thefeeding apparatus for the sets of core sections will now be described.This portion of the apparatus includes a suitable hopper 99 disposed atthe lefthand end of the machine as viewed in the figures and means forfeeding the two outer cover sections 10 and 11 sequentially from theunderside thereof. These sections are stacked one upon the other andarranged in the same relative positions within the hop per 99 that theywill assume when placed on the cover material 13. Thus the hopper isprovided with two independent sections 169 and 101 having adjustablewalls to accommodate core sections of different sizes as would beencountered in different sized books. Inasmuch as structures of thischaracter are well-known in the art it is felt that further descriptionis unnecessary.

The core sections iii and 12 are fed simultaneously from the hopper 99by a reciprocable feeder 21 actuated by an elongated link 162 coupled toa suitable crank 1&3. The link 16?; is provided with an elongated slotlltld for adjustably connecting it with the feeder 21 so that differentlengths of core sections can be readily accommodated. While only onefeeder link 192 is illustrated it is apparent that a similar leverarrangement may be duplicated on the opposite side of the apparatus inorder to effect more uniform operation. The feeder 21 is guided in itsforward travel in a path substantially parallel with the travel of thecore material through the machine and for this purpose suitable tracksor guides m5 may be employed.

In handling relatively thin core sections it is often ditficult toinsure proper feeding of a single section at a time. In order to attainthis end, two. suction cups 166 are provided on the under side of thehopper 99 for contact with each of the core sections. Each .of thesesection cups 1064s connected to a suction jtube sprocket wheel 1stthrough a chain 1::

107' and ispivoted at 1838 :so that just prior to the operation :of thefeeder 21 the suction cups 1% will be pulled downwardly to permit theirrespective core sections to be fed between the rollers 15 and 15'.Actuation of these suction cups 1th: in this manner is accomplished bymeans of a rotary earn 1%? driven by a sprocket wheel 110, a chain 111and a sprocket wheel carried on the end of a shaft 113 which carries thecutting blades 22.

' The central core section 12 is customarily of relatively thin materialand is preferably provided in roll form as indicated at 114 in Fig. 3.This material is withdrawn from the roll 114 by a pair of positivelydriven rollers 115 and 116 coupled by gears 1'17 and Each roller has aflattened portion so that as they are rotated an intermittent drive willresult. The strip 11 is then fed past the cutting station having a knife11% carried by a rotary member 12 1 on shaft 121 and a fixed cooperatingbacking block 122. The bladc'or knife 119 is rotated by a gear 123driven by cooperating wide e gear 124. Following the cutter 119, thesevered strip passes between a second set of drive rollers 125 126coupled by gears 127 and 128. The strip is then carried by a vacuumroller 129 and deposited on the web 13 along With the core sections and11. The vacuum roller 1-29 is carried by a shaft 13%; that is drivenfrom gear 124 by spur gears 131, 132 and The rollers 115 and 125 aredriven from the gear 123 by means of intervening idlers 13 i and 135. Byproperly proportioning the distances between the feeding elements forthe core section 12, sections of any predetermined length may beobtained and the space between successive lengths can be determined bythe depth of the flattened portions on rollers 115 and 116.

As pointed out in connection with Figs. 1 and 2, the cutting blades 22,23 and 27 and the rotary blade members 34 and 42 are driven at a uniformspeed, one relative to the other. For the purpose of simplifying thedescription reference is now made to the cutter 27 which has anelongated blade 136 mounted in axial alignment on the roller 1.1". Thisroller is carried by the shaft 138 pivoted in the frame members 61 andat. One end extends through the frame member 61 and carlies a spur gear139. This spur gear is driven directly by the motor 49 through spurgears 1 51i, 14 1 and 1A2. ,IRotary motion ofthe gear 139 which rotatesthe cutter 26 is transmitted through a series of idler gears 143 to 147to a spur gear 148 carried on the end of a shaft 149. This shaft 14-9extends between the ante members 61 and 62 and carries a pair of collarsand 151, each carrying a cutting blade 23 as described in connectionwithFig. 1. Thus we find that the cutters 23 operlate in absolutesynchronisrn at all times with the elongated cutter 27. Similarly thespur gear is coupled throughthe gear 124 to the spur gear 1.31 on theshaft .113 which has a pair of, adjustable collars 153 and 154 carryingthe blades 22. The collars d and ;on the shaft 149 and the collars 153and 154 on the shaft 113 are adjustable transversely in order to ac-.commodate different widths of covering material that -may be employed.

Referring again to the spur gear 139' mounted on the shaft 13% whichcarries the cutter 27, a sprocket wheel 155 fixed to the end of thisshaft 1&2 drives a which in turn :rotates the shaft 158 carrying therotary plate member "34' functioning to fold the leading edge of thecovering material over the core sections 159,11 and 12 as described.

It Will be observed that the bell crank which drives With the apparatusthus far'described, core sections 14 11 and 12 are fed in groups ontothe continuous web 13 whereupon the two pairs of knives 22 and 23function to remove V-shaped sections from the edges of the web disposedbetween the succesivc sets of core sections. The web then passes throughthe side guides 26 and 26 which function to fold the marginal edges .13and 25 of the web over the adjoining core sections and Since the cementapplied to the web from the container or is on the top side of the webthe marginal'edges 28 and 2? when folded over wi l be firmly cemented tothe core sections.

The small triangular portions or corners 3t 30, 31, 31 of the webs 28and 29 must now be firmly pressed against the underlying portions of theweb in order to effect a secure, neat corner for the book cover or case.his is attained by the earns 32, 32, and 3-3, 33' placed adjacent theside edges of the web.

These cams are driven from gear through a gear 161 and two branch geartrains, the gear train for cams 32, 32' including gears 162, 1152i and16%, shaft 159, bevel gears 1% and res, and vertical shafts 165, thegear train for earns 33, 33 including shaft 17%, bevel gears 171, 173and vertical shafts 172.

With specific reference to the cam the upper end of the vertical driveshaft M55 carries, as shown in Fi 6, a disc 167 fixedly mounted thereonand having a pin extending from the surface thereof. The cam 32 ispivoted at thecenter of the disc and is adapted for movement relativethereto. cam however is imparted by means of the pin iesdand a spring169 normally holding the cam against the pin 168. The cam '32 issimilarly arranged and like primed numerals have been used to designatecorresponding elements.

Reference is now made to Figs. 6 through 16 showing the cooperation ofcam 32 with the web 13 to crease or tuck the corner 3% of the marginaledge 28. It will be apparent that the cam 32 functions in an identicalmanner on the opposite side of the web. In Fig. 6 the can; 32 is shownmounted on the plate 17 with the spring 16* securing the cam against thepin 16%. It will be noted that the web is traveling to the right andthat the cam 32 is moving in a clockwise direction. The cam iscoordinated with the web so that as the outer end of the cam 32 whenoverlapping the web 12; actually engages it precisely at the leadingedge of the core section 11 and rides over the overlapping portion 315.This precise position is illustrated in cross section in Fig. 9 whichshows the cam 32 about to engage the sloping overiapping section 31 ofthe marginal edge 2?. 7

As the end of the cam 32engages the reading edge of the core section 11the latter carries the cam away from the pin 158 against the action ofthe spring 1 69' as shown in Fig. 7. Thus the spring urges the end ofthe cam firmly in contact with the leading edge-of the core section 11as shown in "Fig. l0 and this causes the overlapping portion 311 of themarginal edge 28 to liefiat against the underlying web 13. Fig. 8 showsthe next step in the process wherein the cam 32 moves out of engagementwith the leading edge of the core section 11 whereupon the pin 1&3 movesinto contact with the cam 32 and proceeds to move it through its nextcycle.

The cams 33 and 33 function somewhat similarly to the cams 32 and 32'.The cam 32 is mounted centraily of a plate or disc 1'74 driven by theshaft 172 in a crockwise direction and rotary motion is imparted to thecam by means of a pin 175 and a spring 176m much the same manner as tothe cam 32. his to be noted howeverthat in thecase of the cam 33 the pin175is onthe The operation of the. cam ,33 is: illustrated .in .greate'rRotary movement of the 9 detail inFigs. 6 and 11 through 14. Fig. 6shows the relative positions of the cams 32 and 33 when the cam 32 isabout to engage the web 13. After the cam 32 has finished its operationon one core section, the cam 33 proceeds toe engage the adjoiningoverlapping section 31 of the marginal edge 28 as shown in Fig. 11. Asengagement of cam 33 is attained the pin 175 moves away from the cam 33and the latter is held in engagement with the trailing edge of the coresection 11 by the action of the spring 176. As the web 13 moves to theright the cam 33 fully engages the overlapping section 31 as shown inFig. 12 and firmly presses the marginal edge portion 31 down against theweb 13 as shown in Fig. 14. It will be observed at this point that thepin 175 is still in advance of the cam 33. As the web 13 continues tomove to the right as shown in these figures the cam 33 finally leavesthe web and snaps into the dotted line position shown in Fig. 13,whereupon it is carried through a circular path for operation on thenext successive overlapping marginal edge section 31. a

After leaving the cams 32 and 33, the successive cover assemblies aresevered one from the other by the cutter 27 as previously described. Therollers and 20' then drive the severed book cover assembly against thelower edge 177 of the rotary plate member 34 constituting the first foldover station to fold the leading marginal edge section 35 over onto thecore sections 10, 11 and 12. This rotary plate member has been describedas being driven directly in synchronism with the cutters 22, 23 and 27.It may be desirable however to interpose a clutch between the sprocketwheel 156 and the drive shaft 158 and control the rotary speed of theplate member 34 so that it will have a linear speed at the moment theleading edge of a book cover assembly engages it that is slightly slowerthan the linear speed of such assembly. In this way a tighter fold willbe obtained and the forward motion of the plate portion 177 will beattained, partially under the action of its drive shaft 158 andpartially by reason of the force exerted by the cover assembly' inengagement therewith. The assembly then passes between the rollers 36and 36' to firmly cement the leading edge 35 onto the adjoining edges ofthe core sections, whereupon it is moved into engagement with the springloaded cushioning bar 37 at the second fold over station. Inasmuch asthe length of the core assembly is slightly greater than the distancebetween the core. and the intersection of rollers 36 and 36 it will beforced to the right, as viewed in Figs. 3, 4 and 5, against the actionof the compression springs 39. As soon as the trailing edge of theassembly leaves the rollers 36 and 36' a second rotary plate assembly ordepresser 42 engages the top side of the assembly, forcing it over ashield 41 disposed about the periphery of the roller 43. This actionmoves the trailing marginal edge 40 upwardly to form a secure creasewhereupon the bar 37 then moves to the left to force the leading edge ofthe core assembly between the rollers 36 and 43 to firmly cement thetrailing marginal edge 40 to the core sections. The finished assembly isthen discharged onto a suitable belt 178.

Rotation of the depresser assembly 42 is accomplished by means of asprocket wheel 179 carried on the shaft 158 of the rotary plate assembly34, a chain 181) and a second sprocket wheel 18] securely fastened to ashaft 182 for driving the pusher assembly 42.

It will be observed from the foregoing description of this apparatusthat the cover assemblies are in continuous motion throughout the entirefabrication procedure.

Before discussing, in furher detail, the operation of the controlmechanism for attaining precise coordination between the core sectionsand a printed web material it may be pointed out that the blade 136 ofthe transverse cuter 27, previously described. and which cooperates withan underlying stationary blade 136' is arranged at a slight anglerelative to the frame members 61 and 62 in order to efiect anaccuratetransverse ejit when severing.

one cover assembly from the next. It is of course also apparent that thecutters 22 and 23 function in connection with fixed blade members 22 and23' positioned beneath their respective cutting blades. Moreover, sincebooks are of varying sizes, the web 13 required for covering the coresections will of course vary in width. To accommodate for thesevariations the cutting blades 22 and 23 are adjustably mounted on theirrespective shafts so that they can be readily moved toward and away fromone another. Similarly the guides 26 and 26' for folding the marginaledges 28 and 29 can be adjusted laterally of the apparatus. The earns32, 32' and 33, 33' are also laterally adjustable to accommodatedifferent web widths.

When accommodating different lengths of core sec.- tions it is merelynecessary to readjust the relative speed of the web movement with thefeeding means and other elements driven in synchronism therewith.

Referring now to the electronic controlling mechanism, it was pointedout that the photoelectric assembly 98 produces a series of pulsescorresponding to the velocity marks 44 and possibly the additionalopenings 59 positioned on one edge of the web. This device is coupled ina suitable manner to the correlator 48. In addition, the photoelectriccell 55, light source 53 and lens 54 are housed within a suitable boxdenoted generally by the numeral 183 in Fig. 3. The output of thisphotoelectric cell is also connected to the correlator 48 asillustrated. The perforated disc 52 is shown for convenience in Fig. 3as being carried by the shaft 58 of the speed reducer 56. In this way acorrelation is obtained between the speed of the feeding and cuttingelements versus the speed of the web and assembled cover sections asthey are transported through the apparatus. While it is preferable toarrange the spacing between the successive marks 44 and the spacingbetween the holes 52 and the disc 52 so that under properoperation ofthe apparatus the frequencies generated by each photoelectric cell areequal, it is of course apparent to those skilled in the art that anysuitable relationship may be employed. Through the utilization of asecond set of timing means such as the holes 59 in the edge of the weband the enlarged holes 60 on the disc 52 it is possible to obtainprecise phasing of the operation of the Web relative to the speed of thefeeding means 21 in which case an increased number of marks 44 may beemployed to attain more accurate coordination.

The illustrated embodiment of the invention has been shown as supplyinga single piece of web material 13 for the fabrication of the book coversor cases. In many instances it may be desirable to use a two colorcover, in which case .it would be possible to either print a two colorweb material or feed a. number of different color webs into theapparatus simultaneously in any manner desired. For instance, a centralweb section may be of a white material carrying such information as thebook, title, author and publisher and a pair of side portions of blackmaterial which may or may not carry indicia or designs thereon.

In many instances the center core section 12 may be of a somewhatthinner material than the outer core sections 10 and 11, in which caseit is important to provide means for securing it properly to the webmaterial. This may be accomplished in a variety of ways, as for instanceby the utilization of suitable resilient rollers adapted to aerogeeat IIFrom the foregoing it is apparent that with this apparams accurate andprecise alignment of the core sections and the designs printed on thecovering material will be obtained at all times. Since the various stepsin the process are accomplished while the web and cover assemblies movecontinuously through the apparatus, exceedingly high speeds of operationcan be obtained, generally of the order of two or three times thatheretofore obtainable with known apparatus. Moreover, since precisealignment is secured between the elements forming the cover, thecovering material can be printed in the form of a roll and thus greatlyexpedite the printing process and materially reduce the cost of thefinal production. This saving, coupled with the vastly increased speedsof assembly, results in a considerable overall reduction in cost ofmanufacture.

While only one embodiment of the invention has been shown and described,it is apparent that modifications, changes and alterations may be madewithout dcparting from the true scope and spirit thereof.

What is claimed is:

1. Apparatus for making articles having at least one core section facedon at least one side with a covering material folded over the edgesthereof comprising means for continuously feeding a Web of coveringmaterial into said apparatus, means for periodically feeding coresections on to said web in predetermined spaced relation ship, said coresections having a width narrower than the'width of said web to leavemarginal edge portions of the web extending beyond the core sections,means for notching the edges of said web between successive coresections, longitudinal guides on each side of said web for engaging theside marginal edges and folding them over adjoining edges of said coresections, a rotary knife for severing each leading core section and theassociated covering material from the web along a transverse lineextending between opposite notches to leave leading and trailingmarginal edges of covering material in advance of and behind each coresection, a rotary plate member successively engaging the leadingmarginal edge of the second length of covering'material and folding itover the edge of the corresponding core section, a stop for successivelyengaging the leading edge of each core section, a pair of cooperatingrollers spaced from said stop for successively engaging the trailingedge of the severed covering material, one of said rollers functioningto move the said trailing edge of each section downwardiy to the pointof contact with the other of said rollers to bend the trailing marginaledge upwardly, and means for feeding said section between said rollersto complete the fold of said trailing'edge and discharge the finishedarticle. I 1 a 2. Apparatus according to claim 1' wherein said web a ofcovering material bears on onesid'e a series'of repeated designs one foreach length to be severed from said material, the designs having asubstantially regular but indeterminate spacing greater than the minimumrequisite,

and wherein said apparatus includes means for controlling the relativecore feed speed and web speed for accurately aligning each core sectionwith one of" said repeated designs. a Y i s 3. Apparatus according toclaim Z wherein said controlling means is respon'siv'e'to the rate of'movementof said designs past a predetermined point. A

4. Apparatus according. to claim 2 wherein said appa- 'ratus'includesmeans forsecuring the side marginal edge 7 portions extending beyond theassociated core section firmly to the underlying portions of said web.

5. In apparatus for making covers having acore and a facing onat leastone side folded about-theedgesof the core, means for folding the leadingmarginal edge of material comprising a rotary plate 'and means forfeeding said core and cover material against said-platewhile it ls-inclined upwardly and away-from said leading-edge,

said feeding means-including means-tor continuously away from and out ofthe path of said core and cover to complete the fold.

6. In apparatus for making a cover assembly having a core and a facingon at least one side folded about the edges of the core, means forfolding the trailing edge of material comprising a stop, a pair ofrollers one below the other for feeding the leading edge of the coreagainst said stop, a third roller below and cooperating with the lowerroller, and means for moving the trailing edge of said core downwardlyover the periphery of said lower roller and for folding the trailingedge of cover material over said core while it is between the two lowerrollers so that the said cover moves therebetweento secure the trailingedge fold.

7. In apparatus for making a cover assembly having a core and a facingon at least one side folded about the edges of the core, means forfolding the trailing edge of material comprising a stop, a pair ofrollers one below the other for feeding the leading edge of the coreagainst said stop, a third roller below and cooperating with the lowerroller, and means for moving the trailing edge of said core downwardlyover the periphery of said lower ro.ler and for folding the trailingedge of cover material over said core while it is between the two lowerrollers so that the said cover moves therebetween to secure the trailingedge fold, said third roller being provided with a peripheral shield forengagement of the trailing edge of the cover assembly as the latter ismoved downwardly and said apparatus further includes pusher means formoving said trailing edge downwardiy over said shield.

8. In apparatus for making a cover assembly having a core and a facingon at least one side folded about the edges of the core, means forfolding the trailing edge of material comprising a stop, a pair ofrollers one below the other for feeding the leading edge of the coreagainst said stop, a third roller below and cooperating with th'e lowerroLer, and means for moving the trailing edge of said core downwardlyover the periphery of said lower roller and for folding the trailingedge of cover material over said core while it is between the two lowerrollers so that the said cover moves therebetween to secure the trailingedge fold, said stop being resiliently mounted for movement. away fromsaid rollers upon engagement by the leading edge of the cover assembly.

9. Apparatus for making book covers comprising means for feeding throughalinear path a continuous web of covering material having an adhesive onone side thereof, feeding means for applying successive sets of 7 coresto said web in predetermined spaced relationship, .at least two pair ofdiagonally disposed knives for notching each edge of said web at pointsbetween successive core sets, a pair of longitudinal guidesfor foldingthe longitudinal edge of said web onto said cores, means in the form ofat least one pair of cams for pressing'the portions of said foldedmarginal edges between successive cores downwardly into engagement withthe underlying web portions, a transverse cutter blade for severing eachcore set and the associated web material fro'rnithe preceding core setto providea cover assembly, a'r'otatable plate member for engagement ofthe leadingmar- 'ginal edge of each successive assembly tofolditupwardly and onto the associate core sections, a spring loadedstop, upper and lower cooperating rollers for moving the leading edge ofeach core section against said stop, a "shield disposed about a portionof the'periphe'ry of said lower roller, pusher means for engaging eachcover assembly in engagement with the stop downwardly over said shieldto fold'the trailing marginal edge upwardly, and a third rollercooperating'said lower roller, the third and theilower roller receivingthe trailing edge of each cover assembly to complete the foldand Ifinishedassemblyfrom the apparatus. N a 7 l0. Apparatus accordlngtogclaim 9;:havi' g electron means responsive to the-speed of'operationbf'said feeddischarge the ing means and the movement of saidweb for placing said sets of core sections in predetermined positions onsaid web. 1

11. Apparatus for making articles from web covering material bearing aseries of preprinted designs, one for each article, and a series ofmarkers spaced the same as a group of said designs comprising means forfeeding the web continuously, means for feeding successive sets of coresections onto and securing them to said Web, control means sensing therate of movement of said markers and the speed of said core-feedingmeans to produce corresponding electric signals, means electricallycomparing said signals to automatically modify the speed of saidcorefeeding means'for positioning said sets of core sections inpredetermined positions on said web and means for severing said webbetween successive sets of core sections and folding the edges of theweb over and onto said core sections.

12. Apparatus for making articles from web covering material bearing aseries of preprinted designs, one for each article, and a series ofmarkers spaced the same as a group of said designs and from a set ofcore sections comprising means for feeding the web continuously, meansfor feeding successive sets of core sections onto said web and controlmeans responsive to the rate of movement of said markers and the speedof said corefeeding means to automatically effect alignment of each setof core sections with one of said preprinted designs, andmeansresponsive to the relative speed between said Web and core-feeding meansfor positioning said sets of core sections in predetermined positions onsaid web, said speed-responsive means including a pair of detectors forproducing two sets of electric pulses having a frequency differencecorresponding to said relative speeds of the web and core-feeding meansand a correlator for producing an output voltage proportional indirection and magnitude to said relative speed.

13. The method of making articles including at least one core sectionfaced with a length of covering material folded about the edges thereof,said covering material being in the form of a web continuously carryingpreprinted designs and nominally equally spaced marks along the edgethereof and coordinated with said designs, which comprises feedingsuccessive core sections onto said continuously carrying web ofmaterial, developing electrical signals responsive to the movement ofthe web spaced marks and the movement of the core sections,

comparing the developed electrical signals to produce a correctingsignal to electrically control the feeding rate of the spaced marksrelative to the core sections to accurately align each section with adesign, and then folding the leading edge of the same over the edge ofthe core section, severing the covering material to the rear of the coresection and folding the trailing edge of the web on the trailing edge ofthe core section to complete the article.

14. In apparatus for making a cover assembly having a core and a facingon at least one side and folded about the edges of the core, means forfolding the trailing edge of material comprising a stop, means formoving said cover assembly against said stop, means for moving thetrailing edge of said assembly downwardly, means for engaging the webextending from the trailing edge of the core to displace it relative tothe core during said down- Ward motion, and roller means for engagingthe trailing edge of said cover assembly with the partially folded Webportion to move said assembly in a direction opposite to its movementagainst said stop and fold said web portion tightly about the core.

References Cited in the file of this patent UNITED STATES PATENTS1,807,867 Novick June 2, 1931 1,848,448 Weidner Mar. 8, 1932 1,884,468Winkler et al Oct. 25, 1932 1,946,457 Donnelley et al. Feb. 6, 19342,015,202 Stokes Sept. 24, 1935 2,056,451 Haberstump Oct. 6, 19362,166,038 Chambon July 11, 1939 2,444,685 Waters July 6, 1948 2,556,787Bach et al. June 12, 1951 2,638,147 Nebel May 12, 1953 2,663,352 KellerDec. 22, 1953 2,674,311 Griswold Apr. 6, 1954 FOREIGN PATENTS 496,551Great Britain Nov. 28, 1938

